Method and materials for surface protection

ABSTRACT

The present invention relates to an improved protective composition and method. The preferred protective composition uses near equal amounts by weight or volume of a pre-polymer and curative; however up to three to one amounts of pre-polymer to curative are consistent with the composition and method of the invention. The mixture is applied by a portable spray apparatus using a mixing spray nozzle. For temporary protective coatings using the present invention a releasing agent is applied to the surface to be sealed. The present invention is ideally suited to protect bath tubs, whirlpools, shower stalls, shower pans, tile, marble, glass, metal, hardwoods, other smooth, non-porous surfaces, and the like. The resulting protective coat from the present invention is impenetrable to ladders, boots, sheet rock, mud, paint, dirt, metal pieces, rocks, gravel, sand, grime which might accompany work on or around the protected surface. The present invention also provides a means to avoid scratching, nicking, marring, chipping, staining, painting, and abrading from these and a multitude of other external forces or objects. As a permanent coating, the present invention can guard against weather, water, sun damage, wind damage, or provide attributes specifically needed on certain surfaces such as improved traction for wet or water-exposed surfaces.

CROSS-REFERENCES TO RELATED APPLICATIONS

This application is a continuation-in-part of the inventors' previouslyfiled United States non-provisional application, Ser. No. 10/603,882,filed Jun. 25, 2003, which issued as U.S. Pat. No. 6,767,580 B2 on Jul.27, 2004, and which is a continuation-in-part of the inventors'previously filed United States non-provisional application, Ser. No.09/747,222 filed Dec. 26, 2000, which was published on June 27, 2002 asU.S. Pat. No. 2002/0081383 Al, and which issued as U.S. Pat. No.6,623,805 B2 on Sep. 23, 2003.

STATEMENT REGARDING FEDERALLY SPONSORED RESEARCH OR DEVELOPMENT

None.

REFERENCE TO MICROFICHE APPENDIX

None.

BACKGROUND OF THE INVENTION

1. Field of the Invention

The invention relates to sealing products and improved methods ofapplication to provide an impenetrable and either permanent or quicklyand easily removable durable, protective coating for a variety ofsurfaces or uses.

2. Description of the Related Art Including Information Disclosed under37 C.F.R. 1.97 and 1.98

A search of the prior art located the following United States patentswhich are believed to be representative of the present state of theprior art: U.S. Pat. No. 5,851,618, issued December 1998; U.S. Pat. No.5,193,716, issued March 1993; U.S. Pat. No. 3,657,001, issued December1972; U.S. Pat. No. 5,372,637, issued December 1994; U.S. Pat. No.3,846,355, issued November 1974; U.S. Pat. No. 4,396,681, issued August1983; U.S. Pat. No. 4,511,626, issued April 1985; U.S. Pat. No.4,461,788, issued July 1984; and G.B. Patent No. 1 306 020, issuedFebruary 1973. These references, however, suffer from one or more of thefollowing disadvantages, as more specifically detailed below.

BRIEF SUMMARY OF THE INVENTION

Numerous masking or coating compounds or methods are known in the fieldof art to seal or otherwise protect surfaces or finishes from undesiredcontact with processing or construction unrelated to the surfaces orfinishes. These known compounds or methods, however, do not adequatelyprotect against penetration by foreign objects contacting or otherwiseresting on the sealed surface and which become further forced into thesurface by foot-traffic, accidental dropping, or similar external forcesrelated to construction or repair activities taking place proximately tothe sealed surface area. The sealed surfaces presented in the prior artare most suitable to temporarily protect against paint overspray, sundamage, weather damage, or similar non-impact invasion. These prior artsurfaces, however, lack durability and require time consuming, separateapplications and drying times for any associated release agents plus theprotective surface for removable applications. The prior art applicationmethods do not use individually portable application means, thuslimiting their range and suitability for applications in close quarters.

Also, the prior art require release agents or first barrier coats to bedried before applying the protective coating (see U.S. Pat. No.5,851,618, column 3, lines 53-59). The prior art is similarly limited toprotecting horizontal floor or similarly flat topographies (see, e.g.,U.S. Pat. No. 5,851,618, column 3, lines 23-25).

None of the prior art is durable enough for repeated use on identicalprotective surface topographies.

Some of the prior art teach the use of latex based materials which donot provide suitable protective coatings for the applications using thematerials or methods of the present invention.

Therefore, it is an object of the present invention to provide aneconomical, durable multi-purpose surface coating.

It is another object of the present invention to provide such a surfacecoating which is also quickly and easily applied to any surface in oneapplication.

Another object of the present invention to provide such a surfacecoating which is also quickly and easily applied to any surface withoutrequiring drying of any pre-coat or release agent coating.

It is another object of the present invention to provide such a surfacecoating which can be quickly and easily removed once the activity uponor around the surface, and which activity is being guarded against, hasceased.

It is yet another object of the present invention to provide such asurface coating which can be permanently applied, depending upon theapplication, to guard against weather, water, sun damage, wind damage,or to provide specific desired benefits such as improved traction forwet surfaces.

Another object of the present invention is to provide a method to allowfor portable self-contained applications of such surfaces usingapparatus known in the art.

Yet another object of the present invention is to provide such a surfacecoating which is impenetrable from most activities which would otherwisescrape, chip, gouge, crack, scar, dent, or discolor an unprotectedsurface.

Yet another object of the present invention is to provide such a surfacecoating applicable to unfinished or finished surfaces including, but notlimited to, porcelain, concrete, metal, stone, tile, glass, plastic,wood, or composite materials, regardless of the vertical or horizontalorientation of the finished surfaces.

Yet another object of the present invention is to provide such a surfacecoating in order to avoid scratching, nicking, marring, chipping,staining, painting, and abrading unfinished or finished surfacesincluding, but not limited to, porcelain, concrete, metal, stone, tile,glass, plastic, wood, composite materials, and the like.

It is a further object of the present invention to provide an improvedspray on surface coating application which is durable enough to bereused on surfaces presenting identical surface geometries.

These together with other objects of the invention, along with thevarious features of novelty which characterize the invention, aredescribed with particularity in the claims attached to and forming apart of this disclosure. For a better understanding of the invention,its operating advantages and the specific objects attained by its uses,reference should be made to the descriptive materials in which there aredescribed various preferred embodiments of the invention. Otherfeatures, advantages, and objects of the present invention will becomeapparent with reference to the following description.

BRIEF DESCRIPTION OF DRAWINGS

There are no drawings of the present invention.

DETAILED DESCRIPTION OF THE INVENTION

The detailed description, as set forth below, is intended as adescription of the composition and method of the preferred embodiment ofthe invention, and is not intended to represent the only form in whichthe present invention may be practiced, constructed or operated. It isto be understood that the invention may be practiced by other differentembodiments, which are also encompassed within the spirit and scope ofthe invention.

The preferred embodiment of this invention provides a method forprotecting bath tubs, whirlpools, shower stalls, shower pans, tile,marble, glass, metal, and similar smooth, non-porous surfaces, and thelike, during construction work surrounding such surfaces, or for similarprotective purposes. This embodiment provides a protective surfacecoating composition and portable method which can be quickly and easilyapplied and removed once construction or other activity upon or aroundthe surface, selected to be guarded, has ceased. The removed protectivesurface coating of the present invention's novel method and materialscan be reused for several applications with identical surfacegeometries. Another embodiment further provides a protective surfacecoating that is both durable and applied in a portable single sprayapplication after the surface has been treated with a primary sprayedrelease agent for removable coating applications. Because of the methodof application, this novel finished surface protection is equallyquickly and easily applied within a few minutes to, as well as quicklyand easily removed within seconds from, vertical and horizontal surfacetopographies.

It has been found through testing and experimentation that for generalpurposes the preferred coating formulation for the present invention isa 49%-52% mixture by weight or volume of a pre-polymer mixture tocorrelative percentage of a curative mixture, resulting in a mixture ofwithin 3% equal parts by volume or weight of the two ingredients. Thepresent invention can be practiced with up to a three to one ratio ofpre-polymer mixture to correlative percentage of a curative mixture byweight or volume. For the preferred embodiment, this mixing ofingredients is accomplished at the disposable spray nozzle of a portablespray applicator. Such spray applicators are known in the art andprovide separate product reservoirs which feed through separate, heatedflow lines to the spray nozzle. The heated flow lines allow for theoptimal application temperature of the coating material in thetemperature range from 20 degrees Fahrenheit to 120 degrees Fahrenheit.This preferred embodiment of the present invention is provided by usinga composition of a prepolymer polyurethane from the isocyanateterminated prepolymer family and a curative polyurethane from thehydroxyl terminated polyether polyol chemical family. The preferredembodiment of the present invention uses a blended silicone solution asa releasing agent. These preferred embodiment release agent ingredientsprovide optimal results when applied to surfaces between ambienttemperatures of 20 degrees Fahrenheit and 120 degrees Fahrenheit.

It is a critical feature of the preferred embodiment of the presentinvention that the application means for the protective coatingcomprises an adjustable dual pump sprayer further comprising adisposable spray nozzle tip wherein the pre-polymer mixture and thecurative mixture are mixed at the disposable spray nozzle tip andatomized by compression to provide a four to five inch spray pattern.

All embodiments of the protective coating of the present invention canbe applied using either low pressure, portable spraying systems mountedon manually supported or positioned frames, such as handcarts,backpacks, and the like, or with high pressure spraying systems mountedin a motor vehicle, such as a mini van, and the like. The release agentis applied using a HVLP quart spray gun, or the like, for fine sprayatomization of the release agent and even coverage thereof over theprotective surface.

The prepolymer polyurethane of the preferred embodiment of the presentinvention includes a mixture of: from 35% to 75% polymericdiphenylmethane diisocyanate, preferably 70%; from 7% to 35%4,4-diphenylmethane diisocyanate, preferably 25%; and from 1% to 8%trischloropropyl phosphate, preferably 5%.

The curative polyurethane of the preferred embodiment of the presentinvention includes a mixture of: from 2% to 76% hydroxl terminated poly(oxyalkylene) polyethers, preferably 74%; from 1% to 17.5% butanediol,preferably 17%; from 1% to 9% diethyltoluenediamine, preferably 8.1%;and from 0.5% to 1% of organotin catalyst, preferably 0.9%.

One possible releasing agent of the preferred embodiment of the presentinvention includes a mixture of: from 0.5% to 2% Stoddard solvent,preferably 1.5%; 90% aliphatic hydrocarbon; and from 1% to 10% siliconeblend, preferably 8.5%. An alternate releasing agent for the preferredembodiment of the present invention includes 90% aliphatic hydrocarbonand 10% silicone blend.

Another embodiment of the present invention uses a composition of aprepolymer polyurethane from the isocyanate chemical family whichincludes a mixture of: from 0.5% to 1% of toluene diisocyanate,preferably 0.5%; from 20% to 67% isocyanate terminated prepolymer,preferably 45%; from 4% to 10% diphenylmethane diisocyanate, preferably7%; from 2% to 4.5% higher oligomers of MDI, preferably 2%; from 1% to13% parafinic and naphthenic petroleum blend, preferably 5%; from 16% to58% chlorinated hydrocarbon, preferably 38%; and from 2% to 3%hydrophobic silica, preferably 2.5%. This embodiment of the presentinvention uses a composition of a curative polyurethane which includes amixture of: from 0.2% to 0.6% of an organomercury catalyst, preferably0.5%; from 10% to 17% petroleum hydrocarbon, preferably 15%; from 38% to45% polyether polyols, preferably 43%; from 26% to 37% calcined kaolin,preferably 35%; and from 8% to 12% hydrophobic silica, preferably 6.5%.

The coating materials of either embodiment of the present invention areapplied by a portable spray method which takes advantage of the nearequal parts pre-polymer to curative ratios and the point of applicationmixing afforded by the spray application. The preferred method includesinspection of the surface to be coated to insure that the surface isfree from dust, dirt, abrasive materials, oil, moisture, and any othercondition that would interfere with the application process. Thereafter,the boundaries of the surface to be coated are masked with a suitablematerial, such as masking tape. Preformed, thin sheet metal aprons areuseful in guarding the adjacent surface areas from coating overspray, ifnecessary. Any standard sized functional opening in the applicationsurface for temporary coatings is likewise protected by applying convexpolyvinyl molds or vinyl tape over such opening prior to the applicationof coating materials. Non-standard sized functional openings areprotected using polyvinyl film or vinyl tape known in the art. When theambient temperature is between the optimal range for the coatingmaterials to be used, a releasing agent is applied to the surface to becoated for temporary applications.

Permanent coating applications do not require application of a releasingagent. Prepackaged equal amounts of the coating materials selected foruse are loaded into the portable spray applicator which is fitted with adisposable mixing spray nozzle. The selected coating materials are thenheated to a range of 40 degrees Fahrenheit to 120 degrees Fahrenheit.Once the coating materials reach this preheated temperature, they areapplied to the surface to be coated by use of the portable sprayapplicator. For temporary coating applications, the vertical surfacecoating thickness is typically from {fraction (1/32)} to {fraction(1/16)} of an inch. For temporary coating applications, the horizontalsurface coating surface is typically from {fraction (1/16)} to {fraction(3/32)} of an inch. For permanent coating applications, the applicationcoating thickness is adjusted to suit each particular permanentapplication.

After the initial application of heated coating materials have beenapplied, the applied protective material coating can be adjusted byreapplying the protective material as necessary. The coated surface isallowed to cure, a period which takes between 30 to 45 seconds for thepreferred embodiment. Other embodiments of the present invention providecure time ranges between 10 minutes and 15 minutes, depending upon theambient temperature, relative ratios of pre-polymer and curative, andatmospheric pressure. Once the protective coating has cured, the desiredactivities to be performed upon or around the protective coating and theprotected surface can commence and be completed. If the protectivecoating is temporary, the protective coating and masking materials arequickly and easily removed upon completion of the desired activities bylifting a side loose from the protected surface and pulling the cured,protective coating away from the surface by hand. In this manner, theprotective coating can be removed from standard bath tubs, showerstalls, shower pans, and the like, within seconds of separating acoating side from the protected surface. Similarly, the convex moldedcoatings and the underlying convex polyvinyl molds over any functionalopenings can be easily located and cut open or pulled off by tradesmenneeding to access the opening for repairs, testing, connections, and thelike, while the protective coating covers the protectively coatedsurface.

A critical advantage of the temporary protective coating of thepreferred embodiment over the art is the durability of the removedsurface coating of the present invention which can be reused repeatedlyfor several applications with identical surface geometries. Thisheightened durability feature of the present invention over the artmakes it suitable for high volume, repetitive protective coatingapplications such as standard bathroom fixtures, bath tubs, showerstalls, shower pans, and the like, within the same dwelling or an arrayof dwellings with identical standards for these fixtures.

Another important advantage of the present invention over the art is theability to quickly and easily apply the protective coating layer to thea wet releasing agent layer. The application temperature range for thereleasing agent of the preferred embodiment of the present invention is20 degrees to 120 degrees Fahrenheit. The preferred formulation ofreleasing agent leaves a slippery film on the substrate in even thehighest ambient temperature range from 100 degrees to 120 degreesFahrenheit. The preferred embodiment of the releasing agent of thepresent invention does not dry. This feature greatly lessens the timerequired to prepare and treat multiple surfaces of similar or identicalgeometries and/or topographies. For example, application times forstandard bathroom fixtures, such as bath tubs, shower stalls, sinks,shower pans, and the like, can be as low as three to four minutes.

The method and materials of the present invention are demonstrablysuperior to sprayed latex based agents for the quick application to, andease of removal from, protected surfaces. Sprayed latex agents requirelonger drying times and are not suitable for top-out water testing forbath tubs, shower stalls, shower pans, and the like, since under suchenvironments latex floats to the water's surface re-exposing thepreviously protected surface to the hazards of the construction worksite. The materials of the present invention stay in place while suchwater-testing is performed.

An additional step to provide a gripping surface for the protectivelayer is achieved by broadcasting regular sand granules, or the like, byhand across the protective layer surface just after it has been applied.In this fashion, the sand becomes part of the top of the hardenedprotective layer once it dries, affording traction to the protectivelayer top surface. Because of the durable nature of the protective layerof the present invention, this additional step of providing means fortraction on the protective layer surface does not alter theeffectiveness of the protective layer in guarding the protected surfacefrom any intrusive damage resulting from work activity directly on theprotective layer.

With respect to the above description then, it is to be realized thatthe optimum compositional relationships and methods for the invention,to include variations in size, materials, shape, form, function andmanner of operation, assembly, manufacture, and use, are deemed readilyapparent and obvious to one skilled in the art, and all equivalentrelationships to described in the specification are intended to beencompassed by the present invention.

Therefore, the foregoing is considered as illustrative only of theprinciples of the invention. Additionally, since numerous modificationsand changes will readily occur to those skilled in the art, it is notdesired to limit the invention to the exact composition and methodsdescribed, and further, all suitable modifications and equivalents maybe resorted to, falling within the scope of the invention.

1. A method for protecting surfaces, comprising the steps of: inspectingthe application surface; applying masking materials to protect theapplication surface boundary; protecting any functional openings in theapplication surface using convex polyvinyl molding materials over thefunctional openings; preheating a protective material to a temperatureof 20 degrees Fahrenheit to 120 degrees Fahrenheit; applying a wetreleasing agent to the application surface once an ambient temperaturerange between 20 degrees Fahrenheit and 120 degrees Fahrenheit is met;using an application means to apply the heated protective material tocoat the application surface and wet releasing agent; inspecting theprotective material coating for consistency; adjusting the protectivematerial coating by reapplying the protective material as necessary;allowing the protective material coating to cure; performing work aroundthe coated application surface; completing the work around the coatedapplication surface; locating any functional openings in the coatedapplication surface by the convex protrusion in the coated applicationsurface; opening the functional opening by cutting through or pullingoff the convex protrusion in the application coating and convexpolyvinyl mold thereunder; performing any necessary work to thefunctional opening; completing any necessary work to the functionalopening; removing any masking materials used to protect the applicationsurface; removing the intact remaining protective coating from thecoated application surface; and reusing the intact protective coatingfor surfaces with an identical surface area and geometry as the previousapplication surface without applying any releasing agent or newprotective coating materials.
 2. The method of claim 1, wherein theprotective coating material comprises: between 52% to 75% by weight of apre-polymer mixture; and between 25% to 52% by weight of a curativemixture.
 3. The method of claim 2, wherein the application meanscomprises an adjustable dual pump sprayer further comprising adisposable spray nozzle tip wherein the pre-polymer mixture and thecurative mixture are mixed at the disposable spray nozzle tip andatomized by compression to provide a four to five inch spray pattern. 4.The method of claim 3, further comprising applying the heated protectivematerial to the application surface to a thickness of from {fraction(1/32)} to {fraction (1/16)} of an inch on vertical surfaces and to athickness of {fraction (1/16)} to {fraction (3/32)} of an inch onhorizontal surfaces.
 5. The method of claim 3, further comprisingapplying means to provide a friction surface to the heated protectivematerial before the protective material cures.
 6. The method of claim 5,wherein the means to provide a friction surface to the heated protectivematerial before the protective material cures further comprises applyingsand to the heated protective material after it has been applied to theprotected surface.
 7. The method of claim 3, wherein the applicationmeans is portably housed in a manually carried assembly.
 8. The methodof claim 3, wherein the application means is portably housed in amanually positioned assembly.
 9. The method of claim 3, wherein theapplication means is portably housed in an automotive vehicle.
 10. Themethod of claim 3, wherein the pre-polymer mixture comprises: from 35%to 75% polymeric diphenylmethane diisocyanate; from 7% to 35%4,4-diphenylmethane diisocyanate; and from 1% to 8% trischloropropylphosphate.
 11. The method of claim 3, wherein the curative mixturecomprises: from 2% to 76% hydroxl terminated poly (oxyalkylene)polyethers; from 1% to 17.5% butanediol; from 1% to 9%diethyltoluenediamine; and from 0.5% to 1% of organotin catalyst. 12.The method of claim 3, wherein the pre-polymer mixture comprises: from0.5% to 1% of toluene diisocyanate; from 20% to 67% isocyanateterminated prepolymer; from 4% to 10% diphenylmethane diisocyanate; from2% to 4.5% higher oligomers of MDI; from 1% to 13% parafinic andnaphthenic petroleum blend; from 16% to 58% chlorinated hydrocarbon; andfrom 2% to 3% hydrophobic silica.
 13. The method of claim 3, wherein thecurative mixture comprises: from 0.2% to 0.6% of an organomercurycatalyst; from 10% to 17% petroleum hydrocarbon; from 38% to 45%polyether polyols; from 26% to 37% calcined kaolin; and from 8% to 12%hydrophobic silica.
 14. The method of claim 3, wherein the releasingagent comprises: from 0.5% to 2% Stoddard solvent; 90% aliphatichydrocarbon; and from 1% to 10% silicone blend.
 15. The method of claim3, wherein the releasing agent comprises: 90% aliphatic hydrocarbon; and10% silicone blend.
 16. The method of claim 3, wherein the releasingagent comprises: 1.5% Stoddard solvent; 90% aliphatic hydrocarbon; and8.5% silicone blend.
 17. The method of claim 3, wherein the pre-polymermixture comprises: 70% polymeric diphenylmethane diisocyanate; 25%4,4-diphenylmethane diisocyanate; and 5% trischloropropyl phosphate. 18.The method of claim 3, wherein the curative mixture comprises: 74%hydroxl terminated poly (oxyalkylene) polyethers; 17% butanediol; 8.1%diethyltoluenediamine; and 0.9% of organotin catalyst.
 19. The method ofclaim 3, wherein the pre-polymer mixture comprises: 0.5% of toluenediisocyanate; 45% isocyanate terminated prepolymer; 7% diphenylmethanediisocyanate; 2% higher oligomers of MDI; 5% parafinic and naphthenicpetroleum blend; 38% chlorinated hydrocarbon; and 2.5% hydrophobicsilica.
 20. The method of claim 3, wherein the curative mixturecomprises: 0.5% of an organomercury catalyst; 15% petroleum hydrocarbon;43% polyether polyols; 35% calcined kaolin; and 6.5% hydrophobic silica.